Floor tile

ABSTRACT

A modular floor tile incorporating various features intended to improve the performance of each tile and a system of tiles. Each tile has a top surface, a bottom surface and a perimeter having a sectional thickness and at least one side (in the case of a curvilinear form and a plurality of sides in the case of a rectilinear form), and further includes lateral engaging snap-lock receivers and inserts located at the perimeter of a tile to reduce the incidence of unintended tile separation when assembled into a system; perimeter positioned lands and grooves oriented to prevent fluid migration to a supporting substrate and enhance linkage between tiles when assembled into a system; and under-tile support columns joined by arches at the bottom surface to improve under-tile air flow properties while maintaining sufficient structural support. The floor tiles may further include a biocide.

CROSS-REFERENCE TO RELATED APPLICATION

This is a utility application that claims benefit, under 35 USC §119 (e) to Provisional Patent Application No. 60/677,788, filed 4 May 2005, which application is incorporated herein by reference.

SUMMARY OF THE INVENTION

The present invention is directed towards a modular floor tile that incorporates various features intended to improve the performance of each tile and a system of tiles. Each tile embodiment of the invention has a top surface, a bottom surface and a perimeter having a sectional thickness and at least one side (in the case of a curvilinear form and a plurality of sides in the case of a rectilinear form). In select embodiments according to the invention comprise lateral engaging snap-lock receivers and inserts located at the perimeter of a tile to reduce the incidence of unintended tile separation when assembled into a system; perimeter positioned lands and grooves oriented to prevent fluid migration to a supporting substrate and enhance linkage between tiles; and under-tile support columns joined by arches to improve under-tile air flow properties while maintaining sufficient structural support.

The lateral engaging snap-locks of the invention comprise receivers and inserts. Each receiver, which may be curvilinear, rectilinear or a combination thereof, may extend from at least one lateral edge of the tile or may be recessed thereat. In a preferred series of embodiments, a plurality of loops form the receivers and extend from two sides of the tile if the tile is rectilinear and from at least two distinct portions of the perimeter if the tile is curvilinear. Each loop defines a regular and/or irregular cylinder into which a portion of the insert from an adjacent tile will extend. Preferably, the height of the loop will be less than the height or sectional thickness of the tile such that the loop can be laterally received by an adjacent tile, i.e., that each loop can pass under the bottom surface of an adjacent tile in order to be visually concealed from the top surface when the tiles are arranged into a system of tiles. In such embodiments, the inserts are then disposed on the underside of the tile and provide sufficient clearance there about to closely receive an appropriately positioned loop from an adjacent tile in a system of tiles.

Each insert, which is at least partially formed to fit within the loop, comprises a first portion and a second portion extending away from the lateral edge of the tile or away from the bottom surface of the tile at their respective proximal ends; the distal ends of the two portions are separated by a gap such that upon application of a compressive force, the distal ends can be brought closer to one another. In a relaxed state, at least one dimension of the insert is greater than any dimension of a receiver's internal cylinder. However, upon application of a suitable compressive force, the insert may be inserted into the receiver and permitted to recover at least part of its relaxed-state shape, thereby assuming an engaged position with the receiver to prevent the unintentional separation of one tile from the linked tile. Preferably, at least one portion includes a protrusion to facilitate retention function with an adjacent tile.

In addition to the foregoing, selected tile embodiments of the invention as previously noted may further comprises, with or without the presence of inserts and receivers, at least one perimeter land and at least one perimeter groove. In preferred embodiments, the groove faces “up” while the land faces “down”. When a plurality of tiles is joined to form a system of tile, each land substantially fits in an adjacent groove. This close fit further enhances the linkage between adjacent tiles, and directs any fluids present at the interface between tiles towards the groove. Thus, fluid entering a groove will be directed laterally as opposed to towards a supporting substrate, thereby preserving the condition of the substrate. The land to groove linkage may be loose, a close fit, or interlocking depending upon design considerations and intended usage of the tile systems.

Another feature of the invention pertains to the formation of the tile supporting structure. Embodiments of the invention provide for a plurality of small foot print columns where at least some of the columns are linked to other columns by an arched structure. In this manner, sufficient support for the tile and anticipated loads is accomplished while limiting the amount of tile area contacting the supporting substrate. The arched structure may be of conventional form, e.g., curvilinear, or may be of unconventional form, e.g., rectilinear. By providing for small substrate contacting areas and arched structures, relatively high airflow properties under the tile and between adjacent tiles can be maintained. When used in conjunction with a somewhat resilient tile upper surface capable of minor deflection upon loading, a bellows effect can be achieved, thereby equalizing environmental conditions under a system of interlocked tiles. In a preferred series of embodiments, the column supports are arranged in a hexagonal geometry to produce a strong yet material-usage efficient structure, especially when used in conjunction with a conventional arched structure, column connection arrangement.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an upper surface perspective view of a plurality of tile embodiments according to the invention;

FIG. 2 is an upper surface perspective view of a single tile embodiment according to the invention;

FIG. 3 is a lower surface perspective view of a single tile embodiment according to FIG. 2;

FIG. 4 is a top plan view of the embodiment according to FIG. 2;

FIG. 5 is a bottom plan view of the embodiment according to FIG. 2;

FIG. 6 is a cross section elevation taken along the line 6-6 in FIG. 5;

FIG. 7 is a cross section elevation taken along the line 7-7 in FIG. 5;

FIG. 8 is a composite of FIGS. 6 and 7, shown in a mated association; and

FIG. 9 is a perspective view of two tiles of the embodiment of FIG. 2 prior to engagement.

DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

The following discussion is presented to enable a person skilled in the art to make and use the invention. Various modifications to the described embodiment will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention as defined by the appended claims. Thus, the present invention is not intended to be limited to the embodiment show, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

Turning then to the several Figures, wherein like numerals indicate like parts, and more particularly to FIGS. 2 and 3, upper and lower perspective views of tile 20 of the invention are shown. Tile 20 is preferable constructed of a durable plastic, and preferably includes biocide and fungicide additives to reduce the propensity of undesirable surface growth of biological matter after installation on porous substrates, such as concrete floors generally found in garages and other large enclosed areas. Each tile 20 includes upper surface 30 and lower surface 40. Upper surface 30 is characterized as having a plurality of tread elements 32, intended to increase the coefficient of friction thereon, as is well known to those persons skilled in the art. Lower surface 40 includes a plurality of features, which will now be described.

One feature of the illustrated embodiment concerns the nature of support of tile 20 on a substrate. An objective of this embodiment of the invention is to reduce material usage in creating tile 20, while maintaining or increasing its load bearing properties over the prior art. Moreover, another objective is to provide means for permitting or enhancing fluid flow between lower surface 40 and the substrate, from one edge of the tile to an opposing edge. In this case, fluid flow includes both liquid fluids and gaseous fluids. As discerned from inspection of FIG. 3, lower surface 40 of tile 20 comprises a plurality of hexagonal cells 42, which are defined by support columns 44 at the vertices thereof, and arches 48 spanning the support columns, which establish walls of each cell 42. Support columns 44 provide the primary means for supporting tile 20 on a substrate while arches 48 provide indirect support via their integration with support columns 44. To provide sufficient support to the perimeter of tile 20, perimeter support columns 44′ are further provided there at. As with cells 42, support columns 44′ are discrete to permit ingress and egress of fluids from one edge of tile 20 to any other edge, thus advancing the objective of providing suitable ventilation to the volume defined by lower surface 40 and a substrate.

The use of columns and arches, as well as discrete perimeter support columns, provide the highest degree of support with the least amount of material usage, and further provide convenient fluid pathways from one edge of tile 20 to any other edge, thereby preventing the stagnation of fluids, either liquid or gas, under any given tile. When used in combination with a hexagonal cellular structure, an extremely efficient support matrix is created, both from a load capacity and materials usage perspective.

In addition to incorporating a cellular matrix support structure, tiles 20 provide means for linking adjacent tiles to form an array of tiles, such as is illustrated in FIG. 1. To accomplish this linkage, two forms of interlocking means are preferably used: an insert and receiver arrangement, and a locking land-groove arrangement. As those persons skilled in the art will appreciate, either or both interlocking means can be used.

A first interlocking means is shown throughout the several Figures, and particularly in FIGS. 3, and 5-9, as receivers 50 and inserts 60. Receivers 50, which can casually be characterized as a loop or open ellipse, include upper surface 52, lower surface 54, distal inner surface 56 and distal outer surface 58. Inserts 60 comprise two major elements, namely, head 62 and body portion 74. These two elements together define gap 78. Additionally, head 62 includes distal end 64, bulbous portion 66, outer surface 68, return surface 70 and recessed portion 72; body portion includes contact surface 76.

To establish an interlock between receivers 50 and inserts 60, a pair of tiles 20 are aligned as is best shown in FIG. 9. Once so positioned, the tiles are brought into an overlapping position, and pressed together. The result is the interlock of FIG. 8. As shown in FIG. 8, but also in reference to FIGS. 6 and 7, the interlock is accomplished by the temporary deformation of head 62, as shown by the arrow in FIG. 8. Once lower surface 40 of land 92 clears bulbous portion 66 of head 62, head 62 returns to its initial position wherein lower surface 40 of land 92 closely fits with return surface 70. This interference fit prevents unintended dislodgement between the two tiles, and in particular prevents dislodgement in the vertical direction.

A second interlocking means, namely perimeter interlock 90, is shown throughout the several Figures, and particularly in FIGS. 2-8. Unlike the receiver-insert combination described earlier, perimeter interlock 90 is not intended to materially resist upward dislodgement between interlocked tiles, but instead provides a robust means for resisting lateral, i.e., two dimensional, displacement. Moreover, the second interlocking means provides a degree of liquid fluid insulation of the substrate.

Each tile 20 preferably has two adjacent extending portions 96, which establish land 98, and intrinsic groove 99. Each tile 20 further preferably has two generally continuous grooves 94, each of which is defined by land 92 and tile perimeter portion 92. As illustrated best in FIG. 8, land 98 is sized to snugly fit within groove 94, and land 92 is sized to loosely fit within intrinsic groove 98. The existence of the snug fit between land 98 and groove 94 ensures robust coupling between adjacent tiles and contributes to the overall strength and fluid impervious nature of a tile array as shown in FIG. 1. The existence of the loose fit between land 92 and intrinsic groove 98 ensures freedom of motion of head 62, which is important to the functionality of the receiver-insert interlock feature. 

1. A tile comprising: a panel having an upper surface, an opposing lower surface and a perimeter; a plurality of engagement receivers extending from at least a first portion of the perimeter wherein each receiver comprises an outer surface and an inner surface, and defines a opening; and a plurality of engagement inserts proximate to at least a second portion of the perimeter wherein each insert comprises a head and a body portion, and defines a gap there between.
 2. The tile of claim 1 wherein the head has a bulbous portion and a return surface for retaining the lower surface of an adjacent tile.
 3. The tile of claim 2 wherein the head deforms during engagement with an adjacent tile.
 4. The tile of claim 1 further comprising a plurality of cells formed on the lower surface wherein at least a portion of each cell extends from the lower surface to contact a supporting substrate.
 5. The tile of claim 4 wherein cells comprise a plurality of side walls and verticies defined by the intersection of two sides.
 6. The tile of claim 5 further comprising a plurality of support columns at a plurality of verticies.
 7. The tile of claim 5 wherein at least some of the side walls define an arch having their apex proximate to the lower surface.
 8. The tile of claim 4 wherein at least some of the cells have a hexagonal cross section.
 9. The tile of claim 4 wherein at least one air-path is defined by a plurality of cells extending from one portion of the perimeter to an opposite portion of the perimeter.
 10. The tile of claim 1 wherein one of the upper surface or the lower surface of the tile comprises a groove defined by a perimeter portion of the tile and a spaced apart perimeter land at one portion of the perimeter, and the opposing surface at another portion of the perimeter comprises a perimeter land having a cross section width approximately equal to a cross section width of the groove.
 11. The tile of claim 10 wherein the lower surface comprises a groove defined by a perimeter portion of the tile and a spaced apart perimeter land at one portion of the perimeter, and the upper surface at another portion of the perimeter comprises a perimeter land having a cross section width approximately equal to a cross section width of the lower surface groove.
 12. The tile of claim 1 further comprising a perimeter extension portion wherein the lower surface thereof defines a land and the upper surface of an adjacent edge of the tile defines a groove sized to closely receive the land.
 13. The tile of claim 1 constructed from a material comprising a fungicide.
 14. The tile of claim 1 further comprising a plurality of perimeter colums. 